System and method for the transfer of color and other physical properties to laminate composite materials and other articles

ABSTRACT

A method of transferring a dye to a composite material comprising applying the dye to a transfer media to create a colored transfer media, placing the colored transfer media into contact with the composite material, and applying, using an autoclave, at least one of heat, external pressure, vacuum pressure to infuse the dye to the composite material to create a colored composite material.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. patent application Ser. No.13/727,919, filed Dec. 27, 2012, which is a Continuation-In-Part of U.S.patent application Ser. No. 13/197,741, filed Aug. 3, 2011, (now U.S.Pat. No. 8,343,574), which claims priority to U.S. Provisional PatentApplication Ser. No. 61/370,448, filed Aug. 3, 2010, the contents ofwhich are incorporated herein by reference in their entireties.

BACKGROUND

This invention relates to providing a system and method relating tocoloring laminate reinforced materials.

In a typical prior art embodiment, laminated reinforced materials areplain in color and not conducive to being dyed or colored. One knowntechnique for adding color to laminated material is to paint thematerial. However, painting the material has the downside of the paintflaking off through use and fading in sunlight over time. Thesedrawbacks can be very pronounced in flexible laminate material. Inanother prior art embodiment, laminated reinforced materials arecombined with additional layers of films or other materials to produce afiber reinforced flexible fabric. The other additional materials mayinclude a more traditional woven cloth that is capable of being dyed.Materials of this type are generally found in applications requiringhigh performance and visual or cosmetic appearance is secondary. Thetypical accepted appearance is plain, as manufactured, and/or lackingvisual coloration, patterns, or graphics.

However, it may be desirable in various applications for the consumer tohave more visually appealing material. Thus, it is desirable to producelaminated reinforced materials that are colorable, able to be patterned,or other physical properties, along with the material being resistant tofading.

OBJECTS AND FEATURES OF THE INVENTION

A primary object and feature of the present invention is to provide asystem overcoming the above-mentioned problem(s).

A further primary object and feature of the present invention is toprovide such a system that is efficient, inexpensive, and handy. Otherobjects and features of this invention will become apparent withreference to the following descriptions.

SUMMARY OF THE INVENTION

In accordance with a preferred embodiment hereof, this inventionprovides a method of transferring a dye to a composite material, themethod comprising: applying the dye to a transfer media to create acolored transfer media; placing the colored transfer media into contactwith the composite material; and applying, using an autoclave, at leastone of heat, external pressure, vacuum pressure to infuse the dye to thecomposite material to create a colored composite material. Moreover, itprovides such a method of Claim 1, further comprising cooling thecomposite material to a temperature such that the composite materialmaintains a desired shape. Additionally, it provides such a method ofClaim 1, further comprising curing the dye, by applying at least oneultraviolet or electron beam radiation, to the composite material. Also,it provides such a method of Claim 1, further comprising adding apolyimide coating to the composite material. In addition, it providessuch a method of Claim 1, further comprising adding a polyvinyl fluoride(PVF) film to the composite material. And, it provides such a method ofClaim 1, further comprising adding a nylon coating and a urethanecoating to the composite material. Further, it provides such a method ofClaim 1, wherein composite material is a non-woven material. Evenfurther, it provides such a method of Claim 1, wherein compositematerial is a woven material. Moreover, it provides such a method ofClaim 1, wherein composite material comprises at least one layer ofwoven materials and at least one layer of non-woven materials.Additionally, it provides such a method of Claim 1, wherein the transfermedia is at least one of transfer paper, transfer laminate, or transferfilm. Also, it provides such a method of Claim 1, wherein the dye may beapplied to the transfer media in the shape of a pattern, graphic orlogo, and wherein the colored composite material is infused with amatching pattern, graphic or logo, respectively. In addition, itprovides such a method of Claim 1, wherein the dye is applied to thetransfer media using direct printing. And, it provides such a method ofClaim 1, wherein the transfer media is at least one of transfer paper,transfer laminate, or transfer film. Further, it provides such a methodof Claim 1, wherein the dye may be applied to the transfer media in theshape of a pattern, graphic or logo, and wherein the colored compositematerial is infused with a matching pattern, graphic or logo,respectively. Even further, it provides such a method of Claim 1,wherein the dye is applied to the transfer media using direct printing.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an exemplary embodiment of a rotary color transfersystem.

FIGS. 2A and 2B illustrate an exemplary embodiment of a heated presscolor transfer system and corresponding pressure graph.

FIG. 3 illustrates a flow chart of an exemplary heat press process.

FIGS. 4A and 4B illustrate an exemplary embodiment of an autoclave colortransfer system and corresponding pressure graph.

FIG. 5 illustrates a flow chart of an exemplary autoclave process.

FIG. 6 illustrates an exemplary embodiment of a linear color transfersystem.

FIG. 7 illustrates an exemplary embodiment of a multilayered colortransfer stack.

DETAILED DESCRIPTION OF THE BEST MODES AND PREFERRED EMBODIMENTS OF THEINVENTION

While exemplary embodiments are described herein in sufficient detail toenable those skilled in the art to practice the invention, it should beunderstood that other embodiments may be realized and that logicalmaterial, electrical, and mechanical changes may be made withoutdeparting from the spirit and scope of the invention. Thus, thefollowing detailed description is presented for purposes of illustrationonly.

Materials

Various types of composite materials include both woven materials andnon-woven materials. In an exemplary embodiment, woven materials usemany low denier tows (light weight fibers). The woven material comprisesfibers passing over and under each other in a weave pattern, whichresults in the fibers “crimping”. Also, in woven materials, tensileloading induces transverse loads at fiber overlap sections as crimpedfibers attempt to straighten. The transverse loads reduce thetranslation of fiber strength to fabric strength and decrease long-termfatigue and creep rupture performance. In an exemplary embodiment,higher performance engineering fibers have more pronounced crimp-relatedreduction properties. This is particularly pronounced in fibers withoptimization of axial filament properties and reduced transverseproperties of the filaments.

As used herein, a Composite Material is defined as one or more layers ofunidirectional fiber and polymer matrix plies oriented in one or moredirections. In contrast, in an exemplary embodiment, non-woven CompositeMaterials use high denier tows for easier manufacturability. Thenon-woven Composite Materials comprise fibers that do not pass over andunder each other and thus do not have crimp. An advantage of non-wovenComposite Materials is unlimited fiber areal weights, which is theweight of fiber per unit area. In other words, thicker fibers can beused than in woven materials. Another advantage is the ability to formComposite Materials using multiple layers oriented at any angle relativeto other layers. Furthermore, in an exemplary embodiment, a non-wovenComposite Materials is designed with optimal weight, thickness, andstrength at particular locations or along predetermined load paths asdesired. In addition, non-woven Composite Materials constructed fromhigh modulus fibers may have predictable and linear properties forengineering designs.

In accordance with an exemplary embodiment, a Composite Materials isinfused with color during the manufacturing process. In variousembodiments, the Composite Materials is made from one or more layers ofthinly spread high strength fibers such as, for example, Dyneema®,Vectran®, Aramid, polyester, carbon fiber, Zylon PBO, or other materialsthat are coated with adhesive or other material, or any combinationthereof. The color could be a solid color, a pattern, or any type ofgraphic such as a picture or logo on one or both sides of the compositematerial. The range of infused color is not limited, allowing a broadrange of colored material possibilities. For example, such colorpossibilities include titanium dioxide, carbon black, phthalo blue,quinacridone red, organic yellow, phthalo green, dark yellow orcher,ercolano orange, venetian red, burnt umber, viridian green, ultramarineblue and pewter grey. Other possibilities include manufacturing theComposite Materials to have stripes, polka dots, figures, shapes, andthe like. In an exemplary embodiment, the laminate films and/or fabricscan also have other tints sublimating or non-sublimating, color bases,modifiers or ultra-violet or color stabilizers pre-incorporated tointeract with, synergize, or modify the color process.

In other various embodiments, Composite Materials can also have variouscoatings added to alter the material's surface properties. The variouscoatings can be in addition to, or as alternative to, added color dyesto the material. In a first exemplary embodiment, a film coating isadded to the material. The specific film coating can be used to increaseor decrease the composite's tensile strength, toughness, chemical anddimensional stability, weld-ability, gas barrier properties, electricalproperties, high temperature resistance, ultra-violet or infraredradiation performance, and/or reduce the coefficient of friction. In asecond exemplary embodiment, a polyimide coating is added to theComposite Material. The polyimide coating can alter the electric anddielectric properties of the material. Furthermore, the polyimidecoating may be configured to increase the stability of the materialproperties over a wide range of temperature. In a third exemplaryembodiment, polyvinyl fluoride (PVF) film, such as Tedlar, is added tothe Composite Material. The PVF film facilitates added weatherdurability, long term durability, and environmental stability.Similarly, in a fourth exemplary embodiment, nylon and urethane coatingsboth increase toughness and are flexible, along with lower mechanicaland permeability properties.

In accordance with an exemplary embodiment, a Composite Material islayered with woven coatings to create a Composite Material hybrid. Thewoven coatings can be incorporated to increase abrasion resistance.Furthermore, in an exemplary embodiment, the Composite Material hybridmay be designed to combine the various material properties of theComposite Material and the coatings to result in a high strength,dimensionally stable flexible Composite Material. Examples of CompositeMaterial hybrid applications include military applications such asadvanced visual camouflage and/or infrared signature reduction. Anotherexample is use in a ballistic armor vest.

In an exemplary embodiment, sublimation infusion is implemented toachieve various additions to Composite Materials. The additions mayinclude, for example, color, pattern, and gloss application, specular orinfrared reflectivity modification, anti-microbial or medicines, surfaceadhesion modifiers, nano-material infusion, dielectric modifiers, theprinting of conductive metal or polymer materials to addelectrical/dielectric conductivity features or electrical circuitpatterns, and/or incorporation of fire retardant materials orsynergistic components for fire retardant materials in the laminate,surface films, or surface fabrics. In an exemplary embodiment,ultra-violet stabilizing or curing additives are incorporated into thematerial. These additives can extend the useful life of the CompositeMaterial.

Furthermore, in various embodiments, a fire retardant adhesive orpolymer is used with the Composite Materials. Furthermore, fireretardants may be added to a flammable matrix or membrane to improve theflame resistance of the composite material. Fire retardants may functionin several ways, such as endothermic degradation, thermal shielding,dilution of gas phase or gas phase radical quenching. Examples of fireretardant additives include: DOW D.E.R. 593 Brominated Resin, DowCorning 3 Fire Retardant Resin, and polyurethane resin with AntimonyTrioxide (such as EMC-85/10A from PDM Neptec Ltd.), although other fireretardant additives may also be suitable as would be known to oneskilled in the art. Additional examples of fire retardant additives thatmay be used to improve flame resistance include Fyrol FR-2, Fyrol HF-4,Fyrol PNX, Fyrol 6 and SaFRon 7700, although other additives may also besuitable as would be known to one skilled in the art. In variousembodiments, fire retardancy and self extinguishing features can also beadded to the fibers either by using fire retardant fibers, ceramic ormetallic wire filaments, inherent fire retardant fibers, or by coatingthe fibers. Examples of fire retardant fibers include Nomex or Kevlar.Inherent fire retardant fibers include fibers that have had fireretardant compounds added directly to the fiber formulation during thefiber manufacturing process. Furthermore, fibers may be coated with asizing, polymer or adhesive incorporating fire retardant compounds, suchas those described herein or other suitable compounds as would be knownto one skilled in the art. In additional various embodiments, any wovenor scrim materials used in the Composite Material may be either bepretreated for fire retardancy by the supplier or coated and infusedwith fire retardant compounds during the manufacturing process. In anexemplary embodiment, ultra-violet stabilizing or curing additives areincorporated into the Composite Material. These additives can extend theuseful life of the material.

The Composite Materials are assembled as a multilayer composite of outersurface layers, which may be colorized or textured, via any of thevarious application methods set forth herein. The outer surface layersmay be unidirectional plies, films, non-woven fabric or felt, wovencloth, weldable thermoplastic membranes, waterproof breathable membranesand fabric scrims. These outer surface materials may have initialcoloring or patterning complementary to the various methods of infusiontransfer, sublimation transfer or roll transfer in order to obtain thedesired cosmetic or visual effect. Additionally, in order to adjust thesaturation, hue, opacity or light transmission of the finished colorizedmaterials various powder tints, colored dyes or sublimation colorantscan also be added to the bonding adhesives or the laminating resincomponent of the unitape layers. In order to further adjust thesaturation, hue, opacity or light transmission of the finished colorizedmaterials one or more tinted, opaque or light blocking film may be addedbetween one or more of the laminate ply interfaces.

There are several applications suitable for the Composite Materials inindustrial and technical textiles, apparel, sporting goods, watersports, boating and sailing materials, sail cloth, hunting and fishing,Balloon and Lighter Than Air vehicles, commercial fabric, upholstery,inflatable structure, military apparel, gear, medical or protectivearticles or devices, tension structures, seismic structuralreinforcement materials, banner and signage and other flexible materialor fabric applications where the high performance, light weight, highstrength, rip and tear resistance, high flexibility, flex life,durability, weatherability and unique characteristics of flexiblecomposite materials are very desirable but cosmetic or visualcoloration, patterns, graphics and other visual properties or effectsare also a significant component of the intended purpose of the materialor product. Properties such as absorption or reflection of variouswavelengths of the ultraviolet, visual, infrared or other regions of theelectromagnetic spectrum and/or surface texture or shape, gloss orsheen, opaqueness, light transmission or blocking, or colorfastness andfade resistance are also desirable.

Since many of these potential applications are consumer oriented such asthe apparel, outdoor, sporting goods, hunting and fishing, water sports,boating and sailing, or medical fabrics or textiles, which have specialrequirements or features such as fire retardancy or fire resistance,anti-odor, anti-mildew or anti-microbial resistance, water resistanceand/or breathability, chemical resistance or abrasion resistance, anycombination of the methods and materials are contemplated to fulfill thedesirable characteristics for the intended application.

Methods of Application of Color

Various methods may be implemented to facilitate the transfer of dye toa Composite Material. These methods generally are of two types ofprocesses: continuous process and batch process. A continuous process isone where material is unrolled at a steady web speed or at steadystepwise stop-and-start rate. The material is assembled, consolidated,colorized, textured and then rewound onto a rewind roll. In batchprocess, the Composite Material constituents and colorants are loadedinto a press, vacuum bag or autoclave and then subjected to aheating/curing process.

In accordance with exemplary embodiments, the various methods of dyetransfer may include heat transferring from a printed or saturatedcarrier; direct printing onto laminate or surface films via ink jet ordye sublimation printer; incorporation of dye, tint, or sublimatingcolor or pattern directly onto or into the Composite Material or matrix;heat transfer onto a Composite Material or film; and bath or dippinginfusion. In an exemplary embodiment, sublimating ink is used for moreresistant and permanent coloring.

In accordance with an exemplary method, color is applied to a CompositeMaterial using a transfer carrier substrate. As an initial step, thetransfer carrier is selected, such as a film or paper. The color appliedmay be a solid color or may be a pattern or graphic, which is placed onthe transfer carrier. In various exemplary embodiments, application of asolid color to the Composite Material may be facilitated through directprinting or transfer onto an intended surface, layer, or interface ofthe laminated material. The transfer process may use at least one of aninkjet printer, a gravure roll coater, a slot die coating head, dip barbath coating, an anilox roll coating, a knife over roll coater, areverse roll coater, and an air knife coater.

In various exemplary embodiments, application of a pattern or graphic tothe Composite Material may be facilitated through use of at least one ofan inkjet printer, a sublimation printer, flexo printer process, aniloxroll printing, and offset printing. Whether a solid color or apattern/graphic is transferred, the transfer carrier substrate is inproximity to the Composite Material, such that heat applied throughvarious methods and systems if a separate carrier is used to transfer,infuse or sublimate the color or pattern onto the Composite Material.

The various systems and processes applied to achieve the color transferto Composite Materials include a heated rotary system, a heated presssystem, an autoclave system, a dye infusion system, a heated linearcolor transfer system and matrix pigment tint coloring.

Heated Rotary System

In one exemplary embodiment and with reference to FIG. 1, a rotary colortransfer system 100 comprises a rotating heated roll 110, a tensionedbelt 120, a roll of material to receive color 130, and a color transfercarrier 140. Rotary color transfer system 100 is a continuousroll-to-roll process for applying color or graphics to materials 130.The material 130 that receives the color may be fabric, cloth, film, orlaminated material. The film or fabric can then be used in themanufacture of Composite Materials. For example, rolls of finishedComposite Materials, film or fabric precursor may be run through rotarycolor transfer system 100 to set or infuse the colors. In an exemplaryembodiment, material 130 may be pre-coated or pre-printed with colorbefore being fed through the belt press portion of rotary color transfersystem 100.

In other embodiments, color transfer carrier 140 may be film or paper.The color transfer carrier 140 can be fed from rolls on an unwind andprocessed through rotary color transfer system 100 to transfer colors orpatterns to material 130, such as film, fabrics, and CompositeMaterials. Accordingly, tensioned belt 120 is in contact with rotatingheated roll 110. Furthermore, material 130 and color transfer carrier140 are processed in contact with each other and rolled between rotatingheating roll 110 and tensioned belt 120. The color can be applied tomaterial 130 via direct printing either in-line or off-line. An in-lineprocess includes applying or coating the colors or patterns to CompositeMaterial, film or fabrics, or color carrier 140 as part of the beltpress portion of rotary color transfer system 100. An off-line processincludes applying or coating the colors or patterns to laminate, film orfabrics, or color carrier 140 as part of a separate batch process beforebeing set up onto the belt press portion of rotary color transfer system100. In an exemplary embodiment, heated rotary belt 120 can be usedinline with a lamination process. Moreover, the color can be transferredfrom color transfer carrier 140. In an exemplary embodiment, a vacuum isestablished between rotating heated roll 110 and tensioned belt 120 tofacilitate color infusion and transfer. Various methods may be used tocreate the vacuum as would be known to one skilled in the art.

In an exemplary embodiment, and as illustrated in FIG. 1, color transfercarrier 140 is closest to rotating heated roll 110 and material 130 isclosest to tensioned belt 120. In other exemplary embodiment, material130 is closest to rotating heated roll 110 and color transfer carrier140 is closest to tensioned belt 120. In an exemplary embodiment,material 130 and color transfer carrier 140 are both individual rollsthat are unwound, processed through the rotary belt process as describedabove, and then rewound onto individual rolls.

Heated Press System

In accordance with an exemplary embodiment and with reference to FIGS.2A and 2B, a heated press color transfer system 200 comprises two plates210 or other similar hard surface, a material to receive the color 220,and a color carrier 230. In another embodiment, heated press colortransfer system 200 further comprises a pressure intensifier layer 240made from natural or synthetic rubber. By way of example, suitable caulrubbers are produced by Torr Technologies or Airtech International. Thepressure intensifier layer 240 is coupled to the inside at least one oftwo plates 210 such that pressure intensifier layer 240 in between twoplates 210 and in contact with Composite Material 220 and/or colorcarrier 230. In an exemplary embodiment, pressure intensifier layer 240has at least some ability to compress. The compression facilitatesadditional pressure to be applied to two plates 210 and transferred tomaterial 220 and color carrier 230. In various embodiments, pressureintensifier layer 240 may have a combination of one or more smoothmirror surfaces, smooth matte surface, and a textured or pattern surfaceto provide a desired surface gloss or texture that complements thecolorants.

In an exemplary process and with reference to FIG. 3, a heat pressprocess 300 includes four primary steps. First, apply a color tint/dyetransfer to the color carrier, which may include Composite Material witha surface film or cloth surface on one or both sides, or may includetransfer paper/film carrier (310). In various embodiments, the film orcloth surface may incorporate a complementary color or pre-printedpattern, image or design on one or both sides of the laminate.Furthermore, transfer paper/film carrier may contain solid color, one ormore color patterns or printed graphics to form an image, design, orpicture. Additionally, the transfer media may also include a smooth ortextured surface to impart a surface with a desired degree of gloss orsmoothness texture pattern on one or both sides of the colorizedsurface. Second, position the color tint/dye transfer in contact withthe Composite Material (320). Third, apply heat and pressure totransfer, sublimate, and/or infuse the color, graphics, textures orpatterns to the materials (330). Temperatures typically range from about70° F. to about 650° F., and pressures range from the minimum to keepmaterials in intimate contact, typically 2 psi, to a maximum of 10,000psi. The temperature and pressure applied depend on the particularcolorant used, the substrates the colorant is applied to, and the degreeof lamination or consolidation required. Fourth, cool the material to atemperature such that the finished article remains flat or in thedesired shape, and such that there is no damage, distortion, ordelamination of the finished colorized material. Once the system is ator below the removal temperature, remove the material and color carrierfrom the heated press (340).

In yet another exemplary embodiment, the heated press color transfersystem further comprises a vacuum to increase the pressure in theprocess. The exemplary vacuum may be created either by enclosing thepress platens within a sealable vacuum chamber or by enclosing thelaminate in a vacuum bag system. The applied vacuum can range from about5 to about 29 inches of mercury (Hg). Once the vacuum has been applied,the assembly is placed into the press such that the press platens applythe appropriate pressure profile during the profile of the heating cycleand cooling cycle.

Implementing a vacuum is beneficial to assist in the sublimationcolorant into the substrate, to lower the temperature at whichsublimation colorant transfer occurs, to remove any trapped air orbubbles from the materials, and to prevent oxidization at highertemperatures. If appropriate, the material may be exposed to ultravioletor electron beam radiation to cure or set curable tints or dyes.

Autoclave System

In accordance with an exemplary embodiment and with reference to FIGS.4A and 4B, an autoclave color transfer system 400 comprises a rigid orreinforced elastomeric tool plate 410 and, optionally, a rigid orelastomeric caul plate 420 inside a vacuum bag 430. In variousembodiments, tool plate 410 is typically a stiff plate having a smoothsurface while caul plate 420 may be thiner and/or more compliant thantool plate 410. Vacuum bag 430 is made of flexible, impermeablematerial, or may be a flexible, impermeable elastomeric diaphragm.Alternatively, vacuum bag 430 may be sealed to the side or outer surfaceof first caul plate 410. Vacuum bag 430 is typically 0.001-0.015 inchesthick nylon or other flexible film with suitable temperate and pressureresistance, which is sealed with a tape or strip of tacky hightemperature caulk. Suitable bag and sealant materials include AirtechSecurelon L500Y nylon vacuum bag and TMI Tacky Tape or Aerotech AT-200Ysealant tape. Moreover, if a diaphragm is used in place of a vacuum bag,the diaphragms are typically low durometer, high temperature resistantsilicone rubber, and generally have a thickness of 0.032-0.060 inches.

In place of direct printing or color transferring to material, autoclavesystem 400 further comprises one or more color transfer carriers 440 anda colorant receiving material or laminate 450. Color transfer carrier440 is placed in contact with receiving material 450, where both arebetween tool plate 410 and caul plate 420. For embodiments with highpressure and temperature operations or with large areas, a permeablefelt or non-woven breather material may be included on top of the caulto allow air to flow freely under vacuum bag 430 in order to provideuniform compaction pressure. One example of a suitable breather materialis Airtech Airweave 10. The air inside vacuum bag 430 is removed via avacuum tap 460, which creates a pressure differential in system 400 toprovide compaction pressure on the part inside the vacuum bag 430. Inexemplary embodiments, vacuum bag 430 may be placed inside a pressurizedautoclave 470, such that the hyperbaric pressure inside autoclave 470,external to vacuum bag 430, is raised to a predetermined level. Thepredetermined level may be ambient atmospheric pressure up to 1000 psito provide compaction force while the pressure under vacuum bag 430 ismaintained at a vacuum of 2 to 29 inch Hg.

In an exemplary embodiment, heat is more easily produced in ahigh-pressure environment and facilitates the transfer of dye toreceiving material 450. The temperature inside the autoclave may be setto a predetermined heating rate profile, temperature hold and cool downprofile. Typical temperature ramp rates vary from 2-50° F. per minute,to temperatures ranging from 70° F. to 600° F., with cool down ratesranging from 2-20° F. per minute. For the cooling profile, cool thematerial to a temperature such that the finished article remains flat orin the desired shape and such that there is no damage, distortion ordelamination of the finished colorized material. Once the system is ator below the removal temperature, remove the material and color carrierfrom the autoclave and remove from the bag. In an exemplary embodiment,autoclave color transfer system 400 is very effective and can beincorporated into a Composite Material autoclave or vacuum bagmanufacturing process.

In an exemplary process and with reference to FIG. 5, an autoclaveprocess 500 includes four primary steps. First, apply a color tint/dyetransfer to the color carrier, which may include laminate with surfacefilms or cloth surface on one or both sides, or transfer paper/filmcarrier (510). The film or cloth surface may incorporate a complementarycolor or preprinted pattern, image or design on either or both sides ofthe laminate. The transfer paper or media may contain solid color, asingle or multi color pattern or printed graphics to form an image,design or picture. The transfer media may also include a smooth ortextured surface to impart a surface with given degree of gloss,smoothness texture pattern on one or both sides of the colorized Second,place the color tint/dye transfer in contact with the Composite Material(520). Third, apply heat and pressure, and vacuum to transfer and/orinfuse or sublimate the color, graphics, textures, or patterns to thematerials (530). Temperatures typically range from about 70° F. to about650° F., and pressures range from the minimum to keep materials inintimate contact, typically ambient atmospheric pressure to a maximum of1000 psi. The temperature and pressure applied depend on the particularcolorant used, the substrates the colorant is applied to, and the degreeof lamination or consolidation required. Fourth, cool the material to atemperature such that the finished article remains flat or in thedesired shape, and such that there is no damage, distortion, ordelamination of the finished colorized material. Once the system is ator below the removal temperature, remove the material and color carrierfrom the vacuum bag tool assembly (540). In various appropriateembodiments, the material may be exposed to ultraviolate or electronbeam radiation to cure or set curable tints or dyes.

Linear Color Transfer System

In one exemplary embodiment and with reference to FIG. 6, a linear colortransfer system 600 comprises a rotating horizontal belt press 610, afilm or membrane 620, and color transfer carrier 630. The endlessrotating belts form a continuous process capable of applying a uniform,continuous consolidation pressure to a Composite Material 650, and colortransfer film or paper carrier 630 to maintain intimate contact forinfusion or sublimation color transfer. The materials are heated to asufficient temperature to perform the color infusion in the pressurizedheating zone and then cooling the Composite Material and color transfermedia to a temperature that is at or below the safe removal temperaturefor the Composite Material. The linear color transfer system 600 may bea continuous roll-to-roll process for applying color or graphics toComposite Material 650. The Composite Material 650 that receives thecolor may be fabric, cloth, film, or laminated material. The film orfabric 620 can then be used in the manufacture of Composite Materials.For example, a web of assembled layers of rolls of finished CompositeMaterial, film or fabric 620 precursors may be run through linear colortransfer system 600 to set or infuse the colors. In an exemplaryembodiment, material 650 may be pre-coated or pre-printed with colorbefore being fed through the belt press portion of linear color transfersystem 610 by means of printer, coater or treater 660. The colorizedComposite Material may then be run through a set of calendar orembossing rolls 670 to apply a smooth shiny or matt surface to theComposite Material or to apply a texture to one or both outer surfaces.The rolls 670 may be heated, chilled or left at room temperaturedepending upon the desired surface finish, surface texture, the exittemperature of the Composite Material from the belt portion of the pressor the specific materials. Typical running speed for the CompositeMaterial web ranges from 2-250 ft per minute. The nip rolls 670 and beltsections of the press 610 can be set either for a predetermined gap or afor a preset pressure to the preset roll gaps or with the gaps set tozero with a preset pressure to ensure full consolidation with a givenpressure distribution. Typical gap settings range from 0.0002″ up to0.125″ and typical pressures range from 5 to 1000 lbf per linear inch ofwidth. The rolls and belt system can be heated to consolidate thematerials and/or transfer, infuse or sublimate into one or both sides ofthe Composite Material. Individual plies may be layed up on the web byhand layup, by automated tape layup or by an automated robotic pick andplace operation. Furthermore, typical heating temperature set pointsrange from 70° F. to 550° F.

Radiation curing systems such as an E-beam or UV lamp array can belocated in-line. One advantage of the linear system is that it canintegrate the assembly of unitape plies into a structural reinforcement,the application of the colorant, the incorporation of the variousarbitrary internal or surface film layers, non woven cloth layers andwoven layers into a multi-step integrated manufacturing process wherebase unitapes are converted to finished colorized roll goods.

Multilayer Composite Material Color Infusion

In an exemplary embodiment, multilayer Composite Material color infusioncan be performed using either a heated press color transfer system, suchas system 200 or an autoclave color transfer system, such as system 400.In either process and with reference to FIG. 7, a multilayered stackcomprising multiple caul plates 710, barrier/breather layers 720, colorcarriers 730 and laminates 740 may be substituted for the single stackof Composite Material and color carrier described in system 200 andsystem 400.

Batch Dye Infusion

In an exemplary embodiment, Composite Material, surface films andsurface fabrics can also have colors incorporated via batch dying orinfusion. In this process, rolls of Composite Material, film or fabricsare saturated with color media or tint and placed in a vessel andexposed to an appropriate heat, pressure or vacuum profile to apply toinfuse color media. The films or fabrics treated in this manner may thenbe incorporated into laminates.

Matrix Pigment and Tint Coloring

In an exemplary embodiment, pigment is added to the adhesive that isincorporated into the unidirectional fiber tape manufacturing processthereby resulting in a color infused unidirectional tape subsequentlyused in the manufacture of the Composite Material. For example, suchcolor additives include titanium dioxide, carbon black, phthalo blue,quinacridone red, organic yellow, phthalo green, dark yellow orcher,ercolano orange, venetian red, burnt umber, viridian green, ultramarineblue and pewter grey. In an exemplary embodiment the colored CompositeMaterial that results from the use of the colored unitape may beadditionally colored using the before-mentioned processes, namely HeatedRotary System 100, Heated Press System 200/300, Autoclave System400/500, Linear System 600, Multilayer Laminate Color Infusion 700,Batch Dye Infusion.

Additional details with regards to material, process, methods andmanufacturing, refer to U.S. Pat. No. 5,470,062, entitled “COMPOSITEMATERIAL FOR FABRICATION OF SAILS AND OTHER ARTICLES,” which was issuedon Nov. 28, 1995, and U.S. Pat. No. 5,333,568, entitled “MATERIAL FORTHE FABRICATION OF SAILS,” which was issued on Aug. 2, 1994, and U.S.patent application Ser. No. 13/168,912, entitled “WATERPROOF BREATHABLECOMPOSITE MATERIALS FOR FABRICATION OF FLEXIBLE MEMBRANES AND OTHERARTICLES,” which was filed Jun. 24, 2011; the contents of which arehereby incorporated by reference for any purpose in their entirety.

Benefits, other advantages, and solutions to problems have beendescribed above with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any element(s) that maycause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as critical, required, or essentialfeatures or elements of any or all the Claims. As used herein, the terms“includes,” “including,” “comprises,” “comprising,” or any othervariation thereof, are intended to cover a non-exclusive inclusion, suchthat a process, method, article, or apparatus that comprises a list ofelements does not include only those elements but may include otherelements not expressly listed or inherent to such process, method,article, or apparatus. Further, no element described herein is requiredfor the practice of the invention unless expressly described as“essential” or “critical.”

Although applicant has described applicant's preferred embodiments ofthis invention, it will be understood that the broadest scope of thisinvention includes modifications such as diverse shapes, sizes, andmaterials. Such scope is limited only by the below claims as read inconnection with the above specification. Further, many other advantagesof applicant's invention will be apparent to those skilled in the artfrom the above descriptions and the below claims.

What is claimed is:
 1. A method of transferring a dye to a compositematerial, the method comprising: a) applying the dye to a transfer mediato create a colored transfer media; b) placing the colored transfermedia into contact with the composite material; c) applying, using anautoclave, at least one of heat, external pressure, vacuum pressure toinfuse the dye to the composite material to create a colored compositematerial; and d) cooling the composite material to a temperature suchthat the composite material maintains a desired shape.
 2. The method ofclaim 1, further comprising curing the dye, by applying at least oneultraviolet or electron beam radiation, to the composite material. 3.The method of claim 1, further comprising adding a polyimide coating tothe composite material.
 4. The method of claim 1, further comprisingadding a polyvinyl fluoride (PVF) film to the composite material.
 5. Themethod of claim 1, further comprising adding a nylon coating and aurethane coating to the composite material.
 6. The method of claim 1,wherein composite material is a non-woven material.
 7. The method ofclaim 1, wherein composite material is a woven material.
 8. The methodof claim 1, wherein composite material comprises at least one layer ofwoven materials and at least one layer of non-woven materials.
 9. Amethod of transferring a dye to a composite material, the methodcomprising: a) applying the dye to a transfer media to create a coloredtransfer media; b) placing the colored transfer media into contact withthe composite material, said composite material comprising at least onelayer of woven material and at least one layer of non-woven material;and c) applying at least one of heat, external pressure, vacuum pressureto infuse the dye to the composite material to create a coloredcomposite material.
 10. The method of claim 9, wherein the at least oneof heat, external pressure, and vacuum pressure is applied using anautoclave system.
 11. The method of claim 9, further comprising adding apolyimide coating to the composite material.
 12. The method of claim 9,further comprising adding a polyvinyl fluoride (PVF) film to thecomposite material.
 13. The method of claim 9, further comprising addinga nylon coating and a urethane coating to the composite material.
 14. Amethod of transferring a dye to a composite material, the methodcomprising: a) applying the dye to a transfer media to create a coloredtransfer media; b) placing the colored transfer media into contact withthe composite material; c) applying at least one of heat, externalpressure, vacuum pressure to infuse the dye to the composite material tocreate a colored composite material; and d) applying ultravioletradiation or electron beam radiation to the composite material to curesaid dye.
 15. The method of claim 14, wherein the at least one of heat,external pressure, and vacuum pressure is applied using an autoclavesystem.
 16. The method of claim 14, further comprising adding apolyimide coating to the composite material.
 17. The method of claim 14,further comprising adding a polyvinyl fluoride (PVF) film to thecomposite material.
 18. The method of claim 14, further comprisingadding a nylon coating and a urethane coating to the composite material.19. The method of claim 14, wherein composite material is a non-wovenmaterial.
 20. The method of claim 14, wherein composite materialcomprises at least one layer of woven materials and at least one layerof non-woven materials.